Alumina low silica refractory



Patented July 15, 1947 ALUMINA LOW SILICA REFRACTORY Theodore Estes Field, Louisville, Ky., assignor to Corhart Refractories Company, Louisville, Ky., a corporation of Delaware No Drawing. Application April 10, 1945, Serial'N'o. 5875615 4 Claims.

The tremendous increase in demand for magnesium and its alloys has emphasized the unsatisfactory performance of presently available refractories for melting and containing the molten metals. It is an object of this invention to disclose a novel heat cast refractory which has proven to be especially serviceable for such uses. By heat cast is meant the complete melting of the ingredients as for example with the techniques disclosed in U. S. Patent 1,615,750 to Fulcher, and shaping into the desired form by casting into molds and solidifying.

The chemical attack by magnesium results from reduction of the oxides of the refractory to metal and simultaneous oxidation of the magnesium to magnesium oxide. In the case of burnt refractories which always have appreciable porosity penetration of magnesium into the pores accelerates this attack. Refractory oxides with the exception of magnesium oxide itself are all subject to some extent to such attack and unfortunately the high melting point of MgO precludes its commercial utilization in the form of a non porous heat cast refractory. I have discovered however that well developed crystals of A1203 (corundum) which can be produced in a heat cast refractory are relatively slowly attacked despite the ready re-- ducibility of this oxide reported in the literature.

The melting point of A1203 (2050 C.) is within commercial ranges and since the pure oxide is available in large quantities from the Bayer process, a non porous heat cast refractory of pure A1203 would appear to be a practical solution to the problem. Because of the high melting point involved however, articles cast from this composition are subjected to high tensile strains in the outer portions which despite the most careful insulation cool more rapidly than the interior of the castings, and the frequency with which this tensile strain exceeds the breaking stress makes commercial production discouraging. A more.

particular object of the present invention there- 7 fore is to disclose a successful modification of a high alumina composition which will at the same time preserve when desirable amaximum alumina content and yet permit commercial recovery of the castings by present techniques of casting in molds which may be of sand and annealing while insulated for example by diatomaceous earth.

' Since such factors as coefilcient of thermal expansion, thermal conductivity, specific heat and diffusivity are not capable of significant alteration for a given composition, the most practical source of relief from cracking is to lower the; elastic constants; of the casting. In practice, minor oxide additionsparticularly if SiOz is included are likely not to crystalliz with themajorphase or phases but to remain as an amorphous glassy matrix. I have found that the elastic. constants and more practically the tendency of a given. heat cast refractory to crack can be. pro-. ioundly affected by minor oxide additions con stituting, with part of the; major oxide, such glassy matrices. It will be recognised that the cooling cycleis limited by the supply of heat. in the casting and the ability to retain it by insu,. lation. As a result, diilerent sizes of castings have diiterent cooling cycles and are differently subjected to tensile strains and may also differ somewhat in, the extent of crystallization, the glassy phase being larger in the smaller castings. It; is therefore desirable that the oxide additions be, not too critical but on the contrary be able to care for a variety of. situations.

Inclusion. of silica and alkali or alkaline earth metal oxides are beneficial under some circumstances but these simpler systems are not satisfactory in other cases. As complexity increases, the number of glassy matrices available becomes almost infinite but all are limited by the fact that in a high corundum composition they will be saturated or supersaturated with alumina and are also limited in the extent to which various oxides may be added without exceedin their own soluafiect its properties by depositing the excess as an additional crystal phase. Since the compositions of such matrices are quite unlike normal glasses or slags, little or nothing has been published on their properties and search for satisfactory compositions is necessarily on a trial and error basis.

Among numerous tests, I have found one com- -v plexg matrix system however which has unique properties and which will be discussed in detail. The necessary oxides in this matrix besides A1203 were found to be zrol, M o and SiOz with alkali metal oxide desirable'but optional. I have further discovered that even FezOs and TiOz in the amounts normally present in the usual commerial raw materials do not destroy the effectiveness of this type of matrix in preventing cracking invthe castings. V I v I Tests were made by casting 4 /2 x 2 /2" x9" bricks" in sand molds 1 /4" thick and annealing bility in the matrix and ceasing to importantly a Although more.

the casting with mold in place in an excess of diatomaceous earth known commercially as Silocel. Under these circumstances the presence of Al203-Zr02-MgO-Si02 matrices. expensive at present and therefore not as practical, LizO may also be substituted for Na20 with.

2% or 10% $102; 1% Na20; 2%, 5%, 8% or moderate success. This is illustrated in the fol.- 10% MgO; 2% BaO; or 7.6% Zr02 each per se 5 lowing table:

proved unsatisfactory. Illustrative results with more complex systems with S102 are given in the While larger amounts of alkali metal oxide may be used to obtain tough castings, for most following table: applications as a refractory the alkalies lower re- Melt A1203 s10. N220 MgO. OaO SrO BaO zro, 53%? 97.0 2 yes. 90.0 5 yes. 97.0 1 yes. 97.0 2 yes. 96.0 2 yes. 95.0 4 yes. 89.8 4.8 yes. 93.0 5.0 yes. 92.5 6 yes. 85.0 7.5 yes. 98.0 1 yes. 97.0 2 yes. 90.0 8 yes. 97.8 1.2 yes. 90.0 8 yes. 97.5 1 yes. 97.8 1.2 yes. 94.7 3 yes. 90.0 8 yes. 90.0 6. 5 yes. 90.0 3.3 yes. 91.7 4.1 yes. 90.0 3.3 no. 88.8 3.5 no. 89.6 2.2 no.

sistance and I therefore prefer to add them only when particularly tough castings are desired and then to limit the addition to around 1% although for special purposes as much as 3% can be safely added.

The ZrO2 also contributes unique features as shown by melt 22 although I have found that adshown in the following table:

Melt A120; 810: MgO NazO T102 ZrOn C802 Cracking s3 87.2 4.0 3.1 1.1 3.3 0.4 yes. 20 88.0 4.0 3.1 1.2 0.2 3.1 no. 34 88.3 4.2 3.1 1.2 3.0 yes.

dition of Na20 to give a five component matrix appears to further increase the toughness of the castings. 'That MgO as a flux has peculiar virtues not possessed by the other alkalineearth metal oxides is shown in the following table:

Both T102 and G202 which are in the'same column of the periodic table with Zr02 produced broken castings in contrast to Zr0'2.

From the standpoint of resistance to molten magnesium, the siliceous matrix is'a disadvantage Cracked Melt A120; S10 MgO 0110 81-0 BaO 2:02 NazO 88.0 4.0 3.1 1.2 no. 87.7 4.1 3.1 1.2 yes. 88.2 4.1 3. 1 1. 2 yes. 88.2 4.1 3. 1 1. 2 yes.

Substitution of Ca0', SrO or Ba0 for MgO gave castings which actually broke into pieces during cooling.

The NazO for such batches may be conveniently added as sodaash, sodium silicate, sodium aluminate or feldspar. Feldspars are also obtainable which are high' in K20 rather than Na20 and I have found that good castings can be made with K20 rather than Na20 added to the c mp-lei amount of additions is shown in the following table.

6 and appears as another-crystal phase. Neverthe- :lESS a definite tendency toward brittleness was noted with titania and higher amounts pro- Melt (A1101 si0, MgO; 'zrioi NaiO Castings duoe cracking. .For the bestresultsIprefer therej I fore to :select raw materials in such a way that 35 91.1 1.0 0.85 118 0.3 Ebad. iron oxide andti-taniaare each kept below'3%.

g j? While 1.9% ZrOz ;is about the least which can 38:: 83:7 410 '311 e11 112' good. he included if crack free castings are to be ob- -tained, this oxide has a low solubility in the 1 'complex.glass phase and vinsome circumstances Izhave found1that8'% total :addi-tionris about crystals begin to separate when 5% ZrOz "is itheminimum-whichecan bezsafely'used. '-I' he=-s.olreached. For compositions high in 'corundum ubility gof MgOand 321192 in :the matrix depends therefore..I--prefer to'stay within these limits. For upon ithe amount of sSiOz and alkali :metal oxide use in some alloys of magnesium however "the presentgand Lfokgreatest emciency vin-ayhigh iaiu- :zirconia crystals are not objectionable despite the mina melt these should not iexceednthe saturaready reducibility of this oxide reported ,in the tion amounts. literature. Insure-found that larger additions 10f These are readily determined for the particular .zirconia, with silica kept below 5%, do not proconditions used by'examining the product -petroduce cracking as found for its analogue, titania, graphically for crystals of ZrOz or magnesium but even 40% .zirconia can be added to givegood spinel. In general, I have found equal additions casting-s. Since theinterlockingcrystal structure of MgO and ZrOz quite satisfactory. Further obtained with two crystal :phases contributes to good compositions are illustrated in the followthe strength and since a satisfactory grade of ing table: baddeleyite ore for the purpose can be obtained more cheaply than the pure alumina it displaces, A1103 s10I MgO o, I prefer to use'thi's system wherever equally satis'factor-y service results. Heat cast refractories in the zirconia-alumina system also show excellent corrosion resistance 8813 410 119 430 to molten glass as disclosed in my U. '8. Patent 2,271,366. Productswith10%13%'SiO2'and'with 'NazO as flux are now widely used in-the glass These relatively pure compositions can be 'conindustry. In the newer application of electricity veniently obtained using zircon as source of zirtothemeltingofglasshowever, considerabletrouconiaWhich thenalso contributes a lesser amount ble has been experienced due to such refractories of "silica. The silica can be conveniently supple- 0 becoming electrically conducting at the elevated. merited from high grade k-yan itaa siliceous caltemperatures involved. Since the conductivity cined magnesite, talc, feldspar or, less economincreases with temperature, the resistance heat ically, as quartz sand. Because of the small developed starts on a'vicious cycle which may reamounlt of calcined fmggrgsifte 01c1 tilllc required, at 40 sult inbdestructiton of the refractory. There are norma inclusion o a oun erein is no a num er of fac ors to be consideredin the elecharmful although material high in this impurity 'trical conductivity of refractories such as amount should be avoided for greatest efiiciency. The of liquid phase formed at the given temperature, alumina may be supplied in the form commonly its chemical composition, its viscosity, the rate used for metal'protiuction by electrolysis. of solution of crystals in the glass phase as tem- While the above compositions have beenmade ,perature is raised, etc all of whichmake predicwith relatively pure materials to withstand the tion at present impossible. As a practical matmost severe service, I have found that theFezOa ter, I have discovered however that reduction of and TiOz impurities of cheaper commercial alusilica to 5% and the substitution of 2% MgO .for minous ores do not seriously interfere with the l Ia2O inithe 29% zirconia-co'runduin system will properties off the glasskpha slehwhicl perrurlilit reitncreasie eleatlil'ical resistance at 1500 C. by a faccovery free rom .crac s. 115 w ere e inor o 0. e higher zirconia types of my imtended use of the 1prodluctfldoes ntot jusigfy tl'e exproved refractory are therefore useful in the pense of-pure ma eria s, e cos can e-re uced electric glass industry, where the greater elecby substituting at least in part, bauxite or by- 5' trical resistance is combined with the greater corproduct alumina for the pure alumina. Good rosion resistance due-to'ZrO2. castings were obtained for example by melting From the cracking standpoint I have found, as the following compositions: in the simpler corundum system, that MgO plays Melt A1103 SiO: 08,0 MgO ZrOz F6203 T10: N010 85.8 4.5 .1 3.0 as .5 1.0 .4 85.0 4.0 .1 as 4.0 1.0 2.0 .2 85.1 3.0 .2 2.0 2.0 3.0 3.0

The iron oxide is appreciably reduced by the a unique part in the complex glass phase, now carbon electrodes during melting and the titania saturated with ZrOz as well as A1203. This is easily exceeds its solubility in the residual matrix illustrated in the following tables:

Melt ZrO, A1103 SiOg MgO CaO N830 K20 F820: IiO: Cracks 0.7 0.2 yes. 18:9 73:3 510 119 0.0 31; 8f; f 18.9 13.1 5.0 0.2 1.0 0.7 0.2 yes.

Melt ZXO: A120 SiOz SrO BaO N330 K20 F6203 'IiO: Cracks 18. 9 73. l 5. 0. 7 0.2 yes. 18. 9 73. 3 5.0 0.7 0. 2 yes. N 18. 9 73. 9 5. D 0. 7 0. 2 yes. 39. 51. 8 5.0 1. 9 0. 5 yes. 18. 9 73. 8 5. O 0. 7 0. 2 yes.

It is seen that with silica as low as 5% neither the alkali metal oxides nor the alkaline earth metal oxides with the exception of MgO are able to prevent cracking. Furthermore even MgO must be present to the extent of at least 1.4% to prevent cracking.

What I claim is: 1. A heat cast refractory composed of indigenous crystals in an amorphous matrix and analytically containing 45% to 92% alumina; 1.9% to 40% zirconia, 1.5% to 5% silica, 1.4% to 7% magnesia, 0% to 3% alkali metal oxide, 0% to 3% On the other hand I have found that the iron oxide and 0% to 5% titania, the totalperamount of MgO beyond the minimum is not centage of said ingredients being at least 95%. critical as shown in the following melts. 2. A heat cast refractory comprising indige- Melt zro, A120; s10, MgO F6203 T10. 0210 Cracks 18.9 v 73.3 5.0 I 1.0 0.7 0.2 110. 18.9 70.8 5.0 4.3 0.7 0.2 0.1 110. 12.9 68.8 5.0 0.3 .7 0.2 0.1 no.

Depending upon the silica and impurities present, MgO will also reach its saturation value as the amount increases and will separate as magnesium spinel, For some purposes the magnesium spinel phase is not objectionable but unless thisis known to be the case I prefer to use less than 7% MgO. Whether or not spinel is separating can be readily determined petrographically and unnecessary excesses thus avoided. If sand molds are used for the castings it is of definite advantage to keep MgO low to prevent burning in.

Other satisfactory compositions are given below.

nous corundum crystals in an amorphous matrix and analytically containin principally 85% to 92% alumina, 1.9% to 5% zirconia, 1.5% to,5 silica, 1.9% to 7% magnesia, 0% to 3% alkali metal oxide, 0% to 3% iron oxide and 0% to 5% titania.

3. A heat cast refractory. comprising indigenous crystals of corundum and zirconia in an amorphous matrix and analytically containing principally 45% to 92% alumina, 5% to 40% zirconia, 1.5% to 5% silica, 1.4% to 7% magnesia, 0% to 3% alkalimetal oxide, 0% t0'3% iron oxide and 0% to 5% titania. v i

Melt ZrOz A1203 SiOa MgO NazO F9203 T102 0210 I have found that when Z1O2 is increased to 4. A heat cast refractory comprising indige- 40%45% the tolerance for FezOa and T102 decreases considerably and it is necessary to use relatively pure materials for such batches. With erated and any combination of raw materials can be used which together Willyielda chemical composition within the indicated limits.

' By principally in the following claims I mean over 95% of the total composition.

MREFERENCES CITED The following references are of record file of this patent:

UNITED STATES PATENTS Name 7 Date Field Jan. 27, 1942 in the Number 

